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1966 6v/12v wiring question
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purehp
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PostPosted: Wed Jul 23, 2025 5:23 pm    Post subject: 1966 6v/12v wiring question Reply with quote

Hello all,

I’m converting my 1966 deluxe to 12v. The question I have is the regulator in the engine compartment do I get rid of it and rewire the wires connected to it.
I’ve found a few full writeups on how to convert a 66 beetle and they remove the regulator. I’ve searched with various keywords with no answer to my question.

Can anyone guide me please.

Thanks in advance.

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PostPosted: Wed Jul 23, 2025 5:35 pm    Post subject: Re: 1966 6v/12v wiring question Reply with quote

If you are using a 12v generator you will need a 12v regulator. An alternator usually doesn't use that kind of regulator, but you can bypass it and make it look stock:

https://www.thesamba.com/vw/forum/viewtopic.phpt=509812&highlight=alternator+regulator

Some alternators don't need regulators

From Dale M

Quote:
IF alternator is a AL 82 (only has B+ & D+ terminals) then no regulator is needed ... Yes alternator with white block for regulator is a AL82 (believer it is either Motorola or early Bosch) ... And you need to extend the ALT lamp (idiot light) wiring from regulator to the D+ terminal on alternator...

Image may have been reduced in size. Click image to view fullscreen.


Quote:
However you can leave the regulator in place as a connection point for the 12 volt power leads connecting battery/alternator/all electrics up forward in car, or you can remove regulator and splice the main leads together... Or follow instructions supplied by Rebel...

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PostPosted: Wed Jul 23, 2025 6:05 pm    Post subject: Re: 1966 6v/12v wiring question Reply with quote

70bus wrote:
If you are using a 12v generator you will need a 12v regulator. An alternator usually doesn't use that kind of regulator,



^^^This ^^^ A 12v system allows you to run either an alternator (no external regulator) or generator (using an external regulator like you have pictured). Any regulator has to be for the system voltage, either a 6v regulator for a 6v system, or a 12v regulator for a 12v system.

Some generators would have a regulator stuck onto the body of the generator, but the wiring is the same it's just mounted to the outside of the generator rather than the side of your engine bay. If you are going new, I believe all new generators use an external separately mounted regulator like you have pictured.
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PostPosted: Wed Jul 23, 2025 6:13 pm    Post subject: Re: 1966 6v/12v wiring question Reply with quote

Also, among the 12v radio and 12v wiper motor and whatnot that you will be sorting out, the 66 has a 9-pin relay down there by your right knee, and those are available in 12v. If I recall, Wolfsburg West has them, or other vendors. Don't throw away your 6v 9-pin relay as they are no longer available and very difficult to come by in working order. There is a hack to create one out of a hand full of ordinary relays that is mentioned in my 66 Bus thread in my signature block, which I had to do when dropping back down to 6v to make use of an old engine.

There are voltage step down units available from 12v to 6v to put in line for the 6v pieces you can't or don't replace with 12v, and those are available from the usual vendors as well.
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PostPosted: Wed Jul 23, 2025 6:21 pm    Post subject: Re: 1966 6v/12v wiring question Reply with quote

Quote:
There are voltage step down units available


Check to see if they will damage equipment first (not playing well with a particular radio, for example), or at least be aware they may get very hot.

Unless you want to keep some rare item, almost everything you need is available in 12v. Wiper motors can be an issue as folks report issues with the 'conversion' kits. When in doubt about wipers, ask Don West!

If you go to an alternator, stand and fan mounting need changed. if you are not running a big stereo or a lot of accessories, I'd just get a 12v gen/reg, wire as you did the 6v, and run it. Very easy to switch back to 6v if you want.
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PostPosted: Thu Jul 24, 2025 11:38 am    Post subject: Re: 1966 6v/12v wiring question Reply with quote

purehp wrote:
Hello all,

I’m converting my 1966 deluxe to 12v. The question I have is the regulator in the engine compartment do I get rid of it and rewire the wires connected to it.
I’ve found a few full writeups on how to convert a 66 beetle and they remove the regulator. I’ve searched with various keywords with no answer to my question.

Can anyone guide me please.

Thanks in advance.

Image may have been reduced in size. Click image to view fullscreen.


Generally when doing a 12V conversion you remove the 6V items and replace with the 12V version...
coil, generator, regulator, starter, bulbs, etc. So remove the 6V regulator and install the 12V one. The generator requires a regulator.

Are you wanting the remove the regulator entirely for some reason?
Many people have run a 12V system with a regulator in the engine compartment with no problems.

Maybe the issue is the earlier engines have the regulator directly on the skinny generator, and the later buses with fat generator the regulator is on the side of the engine compartment. (A stock 66 bus had a fat 6V generator.).. but in a bug when they got the fat generator they moved the regulator out of the engine compartment to under the back seat .
That is not a thing with a bus. That's for a bug.

The 12V bus has the regulator's on the right side of the engine compartment, which is also where it is for the 66 bus with fat 6V generator. So if you want to 12V it just put the 12V one where the 6V one is.

If you specifically want an alternator, you don't use the regulator.
I swapped in a motor with alternator into my 61 deluxe some years back, but left the regulator in place, but am not using it. It is not hurting anything.
As others said, you wire the alternator differently than the generator, and there are a number of threads on converting to alternator.

here is a 6V bus with regulator directly on skinny generator:
Image may have been reduced in size. Click image to view fullscreen.

hope that helps. Very Happy

here is a bug with skinny gen:
Image may have been reduced in size. Click image to view fullscreen.

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Last edited by Clara on Thu Jul 24, 2025 11:49 am; edited 1 time in total
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PostPosted: Thu Jul 24, 2025 11:44 am    Post subject: Re: 1966 6v/12v wiring question Reply with quote

Don't want to hijack the thread, but is there a change date for this?
Quote:
right side of the engine compartment, which is also where it is for the 66 bus


My 5/65 truck had the regulator where OP's is, in factory-made holes. Was a 12v option code, so maybe larger 12v gen dictated that?

Anyways, as Clara said, if going gen put new reg where old one is.
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PostPosted: Thu Jul 24, 2025 12:02 pm    Post subject: Re: 1966 6v/12v wiring question Reply with quote

70bus wrote:
Don't want to hijack the thread, but is there a change date for this?
Quote:
right side of the engine compartment, which is also where it is for the 66 bus


My 5/65 truck had the regulator where OP's is, in factory-made holes. Was a 12v option code, so maybe larger 12v gen dictated that?

Anyways, as Clara said, if going gen put new reg where old one is.


when they went to the fat Generator is when they did that.

I think they used the fat generator with the 1 ton /1500 option, so possible for 1963? but was normal by 66s. I don't know when they went to fat generators for a beetle....
The fat 6V generator has a different regulator than the earlier ones, so that gen and reg are a pair. I think it has more amperage.
like teh 71 bus gen and reg are a pair.

66 owners manual: generator had push on connections, regulator on right:
Image may have been reduced in size. Click image to view fullscreen.


8/64 owners manual:

Image may have been reduced in size. Click image to view fullscreen.

oct 62 owners manual:
Image may have been reduced in size. Click image to view fullscreen.

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PostPosted: Thu Jul 24, 2025 2:35 pm    Post subject: Re: 1966 6v/12v wiring question Reply with quote

Clara wrote:
70bus wrote:
Don't want to hijack the thread, but is there a change date for this?
Quote:
right side of the engine compartment, which is also where it is for the 66 bus


My 5/65 truck had the regulator where OP's is, in factory-made holes. Was a 12v option code, so maybe larger 12v gen dictated that?

Anyways, as Clara said, if going gen put new reg where old one is.


when they went to the fat Generator is when they did that.

I think they used the fat generator with the 1 ton /1500 option, so possible for 1963? but was normal by 66s. I don't know when they went to fat generators for a beetle....
The fat 6V generator has a different regulator than the earlier ones, so that gen and reg are a pair. I think it has more amperage.
like teh 71 bus gen and reg are a pair.

66 owners manual: generator had push on connections, regulator on right:
Image may have been reduced in size. Click image to view fullscreen.


8/64 owners manual:

Image may have been reduced in size. Click image to view fullscreen.

oct 62 owners manual:
Image may have been reduced in size. Click image to view fullscreen.



I think that when the 1500cc became standard for '65 Models the fat generator was used with the regulater on the right side of the engine compartment.
Image may have been reduced in size. Click image to view fullscreen.

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PostPosted: Thu Jul 24, 2025 3:45 pm    Post subject: Re: 1966 6v/12v wiring question Reply with quote

OP, since you will need to get 12v gen/reg or alternator anyways, here's another possibility - stick with a generator BUT get the 38A version. This requires a few parts that can be hard to find, but are out there:

dished fan mounting plate (easy to find)
cast iron gen pulley; important to get proper belt alignment! A little hard to find.
38A regulater. Out there, but sometimes pricey. You can use a 30A regulator, but it will only pass 30 amps, so the extra 8 in the gen aren't available. However you can use one while you look for 38A version.
38A generator - I've seen them NOS or rebuilt for 150 - 200, or have a used one rebuilt for about same cost.

That keeps everything wired and looking stock. Plenty of electrical power.
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PostPosted: Thu Jul 24, 2025 4:52 pm    Post subject: Re: 1966 6v/12v wiring question Reply with quote

Wow, thank you so much for all the replies. Looking back I should have given more information about what I have done so far.

I bought a 12v conversion kit. I’ve already swapped the generator for an alternator. 6v choke to 12v choke. Updated alt stand along with 12v coil. The kit came with a 9pin relay which is next to install along with all the bulbs.

The two wires coming off the alt had corrosion so I made new ones. This made me question if 12v would fry the 6v regulator. I will throw this bit of information. The PO had wired in two solenoid relays. One next the coil and one next to the starter. Obviously they were having issues with the system. Which I encountered as well when I ran the bus for a year before deciding to convert to 12v. One of the solenoids had a blue wire that wasn’t connected to anything. It’s safe to a say I’ll remove that along with the second solenoid one next to the starter?

I’ll add more photos.
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PostPosted: Thu Jul 24, 2025 5:02 pm    Post subject: Re: 1966 6v/12v wiring question Reply with quote

Relay by starter sounds like a 'hot start' setup; if you rewire the bus from front to back that won't be an issue and it isn't needed . Might not be needed on original harness if you clean all connections (and Eric and Barb should be here shortly to list the other things they suggest to improve electrical reliability!).

And yes, 12v does terrible things to 6v units, eventually if not immediately.
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PostPosted: Thu Jul 24, 2025 5:11 pm    Post subject: Re: 1966 6v/12v wiring question Reply with quote

Thank you for the diagram. This makes a lot of sense. If I wire the B+ directly to the starter and D+ to Ign would I tap into an existing wire or run a wire to the front?


70bus wrote:
If you are using a 12v generator you will need a 12v regulator. An alternator usually doesn't use that kind of regulator, but you can bypass it and make it look stock:

https://www.thesamba.com/vw/forum/viewtopic.phpt=509812&highlight=alternator+regulator

Some alternators don't need regulators

From Dale M

Quote:
IF alternator is a AL 82 (only has B+ & D+ terminals) then no regulator is needed ... Yes alternator with white block for regulator is a AL82 (believer it is either Motorola or early Bosch) ... And you need to extend the ALT lamp (idiot light) wiring from regulator to the D+ terminal on alternator...

Image may have been reduced in size. Click image to view fullscreen.


Quote:
However you can leave the regulator in place as a connection point for the 12 volt power leads connecting battery/alternator/all electrics up forward in car, or you can remove regulator and splice the main leads together... Or follow instructions supplied by Rebel...
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PostPosted: Thu Jul 24, 2025 5:14 pm    Post subject: Re: 1966 6v/12v wiring question Reply with quote

I've never wired an alternator - maybe post a pic or at least model number so people who have done the job can better inform you of proper wiring.
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PostPosted: Thu Jul 24, 2025 5:17 pm    Post subject: Re: 1966 6v/12v wiring question Reply with quote

Here is a shot of entire engine currently. I do have one voltage drop but it seems I may need more than one since there’s the wiper motor, radio ?

Image may have been reduced in size. Click image to view fullscreen.





Buggeee wrote:
Also, among the 12v radio and 12v wiper motor and whatnot that you will be sorting out, the 66 has a 9-pin relay down there by your right knee, and those are available in 12v. If I recall, Wolfsburg West has them, or other vendors. Don't throw away your 6v 9-pin relay as they are no longer available and very difficult to come by in working order. There is a hack to create one out of a hand full of ordinary relays that is mentioned in my 66 Bus thread in my signature block, which I had to do when dropping back down to 6v to make use of an old engine.

There are voltage step down units available from 12v to 6v to put in line for the 6v pieces you can't or don't replace with 12v, and those are available from the usual vendors as well.
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PostPosted: Thu Jul 24, 2025 5:29 pm    Post subject: Re: 1966 6v/12v wiring question Reply with quote

6v Gas gauge - some folks say it lasts forever on 12v, some say it will smoke out eventually, and some say they fry quickly. 12v gauges are pretty available because of the 67 models. I don't THINK you can use a volt drop but others may know.

Of course you did the bulbs!
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PostPosted: Thu Jul 24, 2025 5:32 pm    Post subject: Re: 1966 6v/12v wiring question Reply with quote

I had doubts I was doing it correctly. Also some of my wires are different colors which also made me doubt even more.

Here are the wires coming out of the loom and the regulator. I’m assuming the white wire from the regulator to the alt should be green? The yellow wire from the regulator should be blue? In another thread someone removed the regulator and connected the green and blue wires together. Then red 10ga wire from the alt and the battery & the wire coming from the front (ign) together?

Configuration of wires on right side.

Image may have been reduced in size. Click image to view fullscreen.


Close up of wires

Image may have been reduced in size. Click image to view fullscreen.


Alt wiring - white wire should be green? This is the color that was there from PO so I replaced it with the same color.

Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.



[quote="Clara"][quote="purehp"]Hello all,

Generally when doing a 12V conversion you remove the 6V items and replace with the 12V version...
coil, generator, regulator, starter, bulbs, etc. So remove the 6V regulator and install the 12V one. The generator requires a regulator.

Are you wanting the remove the regulator entirely for some reason?
Many people have run a 12V system with a regulator in the engine compartment with no problems.

Maybe the issue is the earlier engines have the regulator directly on the skinny generator, and the later buses with fat generator the regulator is on the side of the engine compartment. (A stock 66 bus had a fat 6V generator.).. but in a bug when they got the fat generator they moved the regulator out of the engine compartment to under the back seat .
That is not a thing with a bus. That's for a bug.

The 12V bus has the regulator's on the right side of the engine compartment, which is also where it is for the 66 bus with fat 6V generator. So if you want to 12V it just put the 12V one where the 6V one is.

If you specifically want an alternator, you don't use the regulator.
I swapped in a motor with alternator into my 61 deluxe some years back, but left the regulator in place, but am not using it. It is not hurting anything.
As others said, you wire the alternator differently than the generator, and there are a number of threads on converting to alternator.
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PostPosted: Thu Jul 24, 2025 5:33 pm    Post subject: Re: 1966 6v/12v wiring question Reply with quote

Thanks for the clarification


70bus wrote:
Don't want to hijack the thread, but is there a change date for this?
Quote:
right side of the engine compartment, which is also where it is for the 66 bus


My 5/65 truck had the regulator where OP's is, in factory-made holes. Was a 12v option code, so maybe larger 12v gen dictated that?

Anyways, as Clara said, if going gen put new reg where old one is.
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PostPosted: Thu Jul 24, 2025 5:34 pm    Post subject: Re: 1966 6v/12v wiring question Reply with quote

Thank you. I should have asked sooner would have saved me some time.

70bus wrote:
OP, since you will need to get 12v gen/reg or alternator anyways, here's another possibility - stick with a generator BUT get the 38A version. This requires a few parts that can be hard to find, but are out there:

dished fan mounting plate (easy to find)
cast iron gen pulley; important to get proper belt alignment! A little hard to find.
38A regulater. Out there, but sometimes pricey. You can use a 30A regulator, but it will only pass 30 amps, so the extra 8 in the gen aren't available. However you can use one while you look for 38A version.
38A generator - I've seen them NOS or rebuilt for 150 - 200, or have a used one rebuilt for about same cost.

That keeps everything wired and looking stock. Plenty of electrical power.
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PostPosted: Thu Jul 24, 2025 5:44 pm    Post subject: Re: 1966 6v/12v wiring question Reply with quote

You DEFINITELY need an alternator expert for this, and I am not one.

However. If that's a 6v regulator hooked to a 12v alternator don't do that. Something will give and fry. UNLESS of course you are just using the old regulator cosmetically and wires from alt are going through it like the person did in my first post.

IF you are using that regulator AND it is a 12v unit it might be ok. Most alternators I've seen use a solid state little box, so please get a better opinion on that.

The light in your speedo cluster is an 'exciter' for the alternator to get it to run, so you do need to connect that.

I would suggest using factory colors if you can, even if just electrical tape on ends of wires, to help sort things out. Red means a certain thing (always hot) in VW wiring, as do all colors.
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